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Old 10-08-2016, 12:45 PM   #1
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Secondary air system

I have a 2003 Boxter S and want to replace the entire secondary air system. I've already replaced the pump, but that did not solve my problem (check engine light and P-codes pointing to secondary air}.

Does anyone know where on the engine the other components are located and the easiest way to get to them for replacement?

I would appreciate any help or hints.

Thx,
Jim

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Old 10-08-2016, 03:35 PM   #2
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Quote:
Originally Posted by jimtucker View Post
I have a 2003 Boxter S and want to replace the entire secondary air system. I've already replaced the pump, but that did not solve my problem (check engine light and P-codes pointing to secondary air}.

Does anyone know where on the engine the other components are located and the easiest way to get to them for replacement?

I would appreciate any help or hints.

Thx,
Jim
I just Googled it and here you go. All the components are reached from the top. Change out the plastic vacuum tank (shown in diagram) as they can crack and cause a leak.
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Old 10-08-2016, 03:49 PM   #3
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A Search of this Forum using that Search tab above just might save you some Money, Frustration and time. Possibly even expand the possibilities.
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Old 10-08-2016, 07:48 PM   #4
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I have repaired SAI issues on three different cars.
-One had a plugged check valve on the line that provides the vacuum source (part #7 in the diagram luv2box posted, but in my case, it was located down near part #6)
-Another had broken vacuum tubing. It was all brittle, so I replaced it completely.
-The other had a bad change-over valve. (part #3 in that diagram) To replace it, I removed the alternator. It is located directly behind the alternator and can not be reached from the top unless you remove the intake manifold -much easier to take the alternator out.

I'd suggest checking for broken vacuum hoses first.
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Old 10-09-2016, 05:57 AM   #5
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I had to have all the components, except the pump, replaced last year. I watched my mechanic replace them all, including hoses, from the top without any issues. The intake manifold comes off easily and quickly without having to take the extra step of opening up the front which will extend the time, and effort, required to do the job.
The problem with the SAS is that when the main on/off valve fails it fails in the open position so the system is still doing its job but full time instead of a couple of minutes when first started. The open position also allows hot air to flow backwards through the system and eventually fries all the other components.
You might start by checking the main on off switch which sits right on top to see if it has failed. If it has plan on replacing all the components, if not it may be one of the other switches/diaphragms or a hose. Since the SAS is a common failure issue with Boxsters I would go ahead and do it all.

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